Process Maintenance Engineer

Position Summary:

The Process Maintenance Engineer is responsible for sustaining, improving, and optimizing manufacturing process reliability and equipment performance. This role focuses on troubleshooting process-related equipment issues, implementing effective preventive and predictive maintenance strategies, and driving continuous improvement initiatives to reduce downtime and increase throughput.

The Process Maintenance Engineer partners closely with Operations and Product Engineering to develop and execute comprehensive maintenance plans for the facility. This includes identifying upcoming maintenance projects, planning major equipment repairs, and evaluating equipment replacement needs. The overarching objective of this position is to maximize equipment availability, enhance productivity, and minimize machine downtime across the plant.

Essential Duties and Responsibilities:

Troubleshoot new and existing products and processes related to design, material, or production issues.

Troubleshoot new and existing products and manufacturing processes to resolve issues related to design, materials, or production.

Respond to emergencies and unplanned equipment breakdowns, ensuring timely resolution and minimal operational impact.

Identify critical spare parts and establish recommended spare parts inventory levels to support asset reliability.

Provide technical guidance on material selection for maintenance activities and capital equipment replacements.

Apply root cause analysis (RCA) and continuous improvement methodologies to resolve recurring issues across diverse manufacturing processes.

Develop and drive Total Productive Maintenance (TPM) and asset reliability strategies to improve equipment uptime and reduce reactive maintenance costs.

Oversee all site maintenance and engineering activities to ensure alignment with operational goals.

Design, implement, and continuously improve preventive and predictive maintenance programs.

Develop maintenance technician troubleshooting capabilities through structured training plans and skill development initiatives.

Manage maintenance workflows using CMMS systems, ensuring accurate work order management, tracking, and reporting.

Analyze downtime, failure modes, and maintenance trends to implement effective corrective and preventive actions.

Ensure maximum equipment uptime, performance, and reliability across all manufacturing assets.

Lead continuous improvement and structured problem-solving initiatives to enhance operational efficiency.

Implement process improvements to reduce downtime, increase throughput, and improve overall equipment effectiveness (OEE).

Support new product introductions and process development, including equipment readiness and maintainability.

Develop standardized preventive maintenance procedures and troubleshooting guides.

Support capital equipment projects, including equipment selection, facility layout, installation, and commissioning.

Manage project schedules, budgets, milestones, and action items to ensure successful project execution.

Analyze, prepare, and distribute technical and project status reports to internal stakeholders.

Collaborate with Environmental, Health & Safety (EHS), engineering, and operations teams to maintain compliance and promote a safe working environment.

Required Skills and Abilities

Strong troubleshooting skills with the ability to diagnose and resolve complex mechanical, electrical, and process‑related issues.

Experience with TPM, Reliability-Centered Maintenance (RCM), or asset reliability programs.

Knowledge of Lean Manufacturing and continuous improvement methodologies.

Experience supporting capital equipment projects, including equipment selection, installation, and commissioning.

Familiarity with automation, PLCs, instrumentation, and industrial controls.

Experience developing standard work, PM procedures, and troubleshooting documentation.

Exposure to predictive maintenance technologies such as vibration analysis, thermography, or oil analysis.

Strong project management skills, including scheduling, action tracking, and stakeholder reporting.

Ability to train and mentor maintenance technicians on troubleshooting and maintenance best practices.

Experience supporting new product introductions and process changes in a manufacturing environment.

Ability to read, write, speak, and understand English sufficiently to follow safety procedures, work instructions, and communicate effectively with supervisors and team members.

Education and Experience:

Associate’s degree in Mechanical Engineering, Maintenance Engineering; or 10+ years of equivalent experience in high-tech manufacturing machine maintenance

Lean Six Sigma Green Belt or equivalent continuous improvement certification.

Excellent problem-solving, communication, and project management skills.

Knowledge in areas such as confined space entry, lockout / tag-out, hot-work permitting, etc.

Knowledge of instrumentation and equipment design and repair.

Basic knowledge of equipment lubrication.

Physical Requirements:

Ability to move around the facility and visit production areas, which may include walking and standing for most of the time.

Hybrid work between GEMBA and office. Candidate must be able navigate both work environments effectively.

Prolonged periods sitting at a desk and working on a computer.

Must be able to lift 40 lbs. at times.

Occasional travel may be required for training or coordination with other VDL locations.